Portable Combustion
Analyzer (PCA)
Instruction 0 0 24-9219
Operation & Maintenance
Product Leadership • Training • Service • Reliability
Rev. 10 – May 2010
WARRANTY
Bacharach, Inc. warrants to Buyer that at the time of delivery this Product
will be free from defects in material and manufacture and will conform
substantially to Bacharach Inc.’s applicable specifications. Bacharach’s
liability and Buyer’s remedy under this warranty are limited to the repair or
replacement, at Bacharach’s option, of this Product or parts thereof returned
to Seller at the factory of manufacture and shown to Bacharach Inc.’s
reasonable satisfaction to have been defective; provided that written notice
of the defect shall have been given by Buyer to Bacharach Inc. withi n two (2)
year after the date of delivery of this Product by Bacharach, Inc. The Oxyge n
(O
) Sensor has a limited warranty of one (1) year. Routine service and/or
2
calibration are excluded from this warranty.
Bacharach, Inc. warrants to Buyer that it will convey good title to this
Product. Bacharach’s liability and Buyer’s remedy under this warranty of
title are limited to the removal of any title defects or, at the election of
Bacharach, to the replacement of this Product or parts thereof that are
defective in title.
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ARISING FROM BACHARACH’S NEGLIGENCE, ACTUAL OR
NOT
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herein to the exclusion of any and all other remedies including, without
limitation incidental or consequential damages. No agreement varying or
extending the foregoing warranties, remedies or this limitation will be
binding upon Bacharach, Inc. unless in writing, signed by a duly authorized
officer of Bacharach.
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Notice:
Product improvements and enhancements are continuous, therefore the specifications and information
contained in this docume nt may change w ithou t noti ce.
Bacharach, Inc. shall not be liable for errors contained herein or for incidental or consequential damages in
connection with the furnishing, performance, or use of this material.
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written consent of Bacharach, Inc.
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Copyright © 2010, Bacharach, Inc., all rights reserved.
A
Instruction 0024-9219
PCA
Contents
1.0
INTRODUCTION
1.1 The Portable Combustion A
1.2 Displayed Data
1.3 PCA Model Configurations
2.0 TECHNICAL CHARACTERISTICS
3.0 SETTING UP THE PCA
3.1 Scope
............................................................................................ 3-1
3.2 PCA Power
3.2.1 Checking and Replacing the Batteries
3.2.2 Using the Optional Power Supply
3.3 Connecting the Probe
3.4 Configuring the PCA
4.0 OPERATION
4.1 Key Pad Functions
4.2 Sampling Hole Location
4.3 Performing a Combustion Test
4.3.1 Analyzer Turn On and Warm Up
4.3.2 Installing Probe in the Stack
4.3.3 Starting a Combustion Test
4.3.4 Ending a Combustion Test
4.3.5 Turning Off the Analyzer and Purging the CO Sensor
4.4 Differential Pressure Measurement
4.5 Warm-up Screen
4.6 Sensor Status Screen
4.7 Combustion Test Screen
4.8 Fuel Sel
4.9 Draft Screens
4.10 Memory Directory Screen
4.11 Memory to PC Screen
4.12 ID Setup Screens
4.13 Temperature Setup Screen
4.14 Draft Unit Setup S
4.15 O
4.16 Language S
4.17 Display M
4.18 Time / Dat
4.19 Printer /
4.20 Calibration / Maintenance
4.21 Maint
Instruction 0024-9219
ection Screen ............................................................... 4-11
Reference Setup Screen
2
enance Screen
............................................................................ 1-1
nalyzer
.......................................... ................................. 1-2
......................................................... 1-3
.................................................................. 3-1
..................................... ........ .......... ........ ....... .......... .. 3-1
......................................... ............... ......... 3-2
..................................... ............ ................. 3-4
..................................................................................... 4-1
...................................................................... 4-1
..................................... ..... .......... ........ . 4-2
......................................................................... 4-8
.................................................................. 4-9
........................................................... 4-10
...................................... ................. ............ ......... 4-12
.......................................... ............ 4-13
............................................................. 4-14
..................................... ...................... ......... 4-17
.......................................... .......... 4-19
creen
......................................... ............... 4-20
..................................................... 4-21
etup S
ode Setup Screen
e Setup Scr
creen
.......................................................... 4-22
.......................................... ......... 4-23
een
....................................................... 4-24
Setup Screen ............................................................ 4-25
Password Screen ........................ 4-26
....................................... ........ .......... ...... 4-27
Contents
........................................... 1-1
..................................... ........ 2-1
........................... 3- 1
.................................. 3-2
.................................................. 4-3
................................... 4-3
.......................................... 4-4
............................................ 4-5
.............................................. 4-5
. 4-6
.......................................... 4-7
i
Contents
4.22 User Na
4.23 Saving Test Data
4.24 Printing Test Data
4.25 Clear Memory Screen
4.26 Resetting the Microprocessor
5.0 CALIBRATION
5.1 Sensor Check
5.2 Calibration Fixtures
5.3 Calibrate Menu Screen
5.4 Calibrate
5.5 Calibrate TS-Span
5.6 Calibrate TA-Zero
5.7 Calib
5.8 Calibrate NX
5.9 Calibrate
5.10 Calibrate
6.0 MAINTENANCE
6.1 Routine Maintenance
6.2 Disassembly
6.3 Cleaning the Probe
6.4 Water Trap/Fil
6.5 Replacing the Particulate Filter
6.6 Replacing the
6.7 Replacing the Nitric Oxide Sensor
6.7.1 Replacing the Nitric Oxide Sensor Filter
6.7.2 Replacing the Nitric Oxi
6.8 Replacing the Carbon Monoxide Sensor
6.8.1 Replacing the Carbon Monoxide Sensor Filter
6.9 Replacing the Pump Assembly
7.0 TROUBLESHOOTING
7.1 Analyzer Repair
7.2 Error Codes
7.3 Troubleshooting G uide
8.0 PARTS & SERVICE
8.1 Replacement Parts
8.2 Accessories
8.3 Service
APPENDIX A – Display Screen Translations
APPENDIX B – Printout Translations
ii
me Screens
.................................................................................. 5-1
................................... ........................................... 5-1
TS-Zero ....................................................................... 5-4
rate TA-Span
............................................................................... 5-8
CO ............................................................................... 5-9
Draft
................................................................................ 6-1
....................................... ....... .......... ......... ...... ........ . 6-2
Oxygen Sensor .......................... ... ....................... 6-7
................................................................................. 7-2
...................................... ........ .......... ........ ....... .......... . 8-2
Centers
......................................... ....................... 4-28
........................................ ............................ 4-29
.................................................................. 4-30
............................................................. 4-32
................................................. 4-32
................................................................... 5-2
............................................................... 5-3
.................................... ....... ........ .......... ....... .. 5-5
....................................................................... 5-6
...................................................................... 5-7
........................................................................ 5-11
......................................... ...................... .. 6-1
..................................................................... 6-4
ter Assembly Mai
..................................................................... 7-1
.......................................................................... 7-1
............................................................... 7-3
.......................................................................... 8-1
...................................................................... 8-1
........................................................................... 8-6
ntenance
..................................... ....... .... 6-6
de Sensor Bias Battery
............................................ .... 6-12
................................................. B-1
PCA
................................ 6-5
........................................ .... 6-8
....................... 6-8
........... 6-9
.................................. 6-10
............ 6-11
..................................... A-1
Instruction 0024-9219
PCA
1.0 INTRODUCTION
Introduction
1.1 The Portable Combustion Analyzer
The Portable Combustion Analyzer (PCA) (Figure 1-1) is a commercial
grade, hand held, combustion efficiency analyzer that is designed for
continuous
furnaces, appliances, and boilers. The basic instrument is supplied with a
probe, instruction manual, batteries, and carrying case.
Instruction 0024-9219
(on demand) sampling of light industrial and residential
Figure 1-1. PCA
1-1
Introduction
1.2 Displayed Data
The PCA directly measures, displays, and stores the following data:
• Room Temperature in °F or °C (Primary Air/Ambient Temperature)
• Flue Gas Oxygen Content in %
• Flue Gas Temperature in °F or °C
• Flue Gas Carbon Monoxide Content (H2 Compensated) in ppm
(For analyzers having a Carbon Monoxide sensor)
• Flue Gas Nitric Oxide content in ppm
(For analyzers having a Nitric Oxide sensor)
• Pressure/Draft in Millibars, Pascals, or Inches of Water Column
(For analyzers having a draft sensor)
• Differential Pressure in Millibars, Pascals, or Inches of Water Column
(For analyzers having a draft sensor)
The PCA will compute, display, and store the following data for any of the
seven standard fuels:
• Combustion Effi c ien cy in %
• Excess Air in %
• Flue Gas Carbon Dioxide Content in %
• Flue Gas Carbon Monoxide Content referenced to Oxygen in ppm
(For analyzers having a Carbon Monoxide sensor)
• Flue Gas Nitric Oxide Content referenced to Oxygen in ppm
(For analyzers having a Nitric Oxide sensor)
The seven standard types of fuels that can be selected are:
• Natural Gas
• Oil #2
• Oil #4
• Oil #6
•
Kerosene
• Propane
• Coal
The PCA continuously monitors flue gas exhaust conditions and updates
the above displayed values during a combustion test. If the analyzer is
equipped with an optional pressure sensor, then draft measurements can
be made simultaneously with the combustion test, or made separately.
The analyzer has the capability of storing data that was collected during
a combustion test or draft meas urem ent . The s tor ed d ata ca n then at a
later date be either viewed on the PCA’s display, printed using an optional printer, or downloaded to a computer.
1-2
Instruction 0024-9219
PCA
PCA
1.3 PCA Model Configurations
Introduction
TABLE 1-1. PCA SENSOR CONFIGURATION S
PCA Models
Standard Advanced
PCA Part No. PCA Part No. Stack Temp., CO NX Draft
Model 24- Model 24- Air Temp. & O
10 8040 40 8140 X
15 8041 45 8141 X X
20 8042 50 8142 X X
25 8043 55 8143 X X X
30 8044 60 8144 X X X
35 8045 65 8145 X X X X
Sensors Installed
2
(
PCA 10 & 40
These basic instruments have the capability of measuring, displaying,
and storing combustion tests. They will also display flue gas Oxygen
content, flue gas Carbon Dioxid e (CO
temperature, combustion efficiency, excess air
2
) content, air temperature, flue gas
, and the current fuel
selected. The ‘standard’ PCA 1 0 stores up to 10 combusti on tests, while
the ‘advanced’ PCA 40 can store up to 100 tests.
PCA 15 & 45 with Draft
In addition to the features of the basic PCAs described above, these instruments have the added capability of measuring, displaying, and saving draft
or differential pressure in either Millibars, Pascals, or Inches-of-Water
Column.
PCA 20 & 50 with Carbon Monoxide Measurement
In addition to the features of th e basi c PCAs d escri bed ab ove, t hese
instruments have the added capability of measuring, displaying, and
saving Carbon Monoxide (CO) content, as well as calculating a CO level
that is referenced to Oxygen. T he ‘st an dard’ PC A 20 c alcula tes CO ref erenced to 0% Oxygen, while the ‘advanced’ PCA 50 calculates CO referenced to a user selected Oxygen level of between 0–15%.
PCA 25 & 55 with Draft and CO Measurement
These instruments combine the features of all the PCAs listed above.
Instruction 0024-9219
P)
1-3
Introduction
PCA 30 & 60 with CO and Nitric Oxide Measurement
In addition to the features of the basic PCAs with CO measurement, these
instruments have the added capability of measuring, displaying, and
saving Nitric Oxide (NX) content, as well as calculating a NX level that is
referenced to Oxygen. The ‘standard’ PCA 30 calculates NX referenced to
0% Oxygen, while the ‘advanced’ PCA 60 calculates NX referenced to a
user selected Oxygen level of between 0–15%.
PCA 35 & 65 with Draft, CO & NX
These instruments are capable of measuring, displaying, and saving all
measurements as previously described.
Printout Capability
All PCAs have the ability to print the latest test data, or any of the saved
tests, to an optional printer via an infrared link.
CO Sensor Purge
On all PCAs that measure CO, if the
reading is 100 ppm or higher, the analyzer will attempt to purge itself of
CO before turning off.
ON/OFF key is pressed while the CO
Advanced PCA Model Features
‘Advanced’ models of the PCA contain the following features that are in
addition to the features of their corresponding ‘standard’ units:
• 100 memory locations
• RS232 output for transferring saved data to a personal computer
• Ability to enter three lines of user-identification information which is
printed at the top of each printout
• Ability to enter three lines of customer-identification information
which is printed with each test record
• Ability to set the Oxygen reference level from 0 to 15% for CO and NX
measurements on analyzers equi pped with a CO or NX s ensor
1-4
Instruction 0024-9219
PCA
PCA
Technical Characteristics
2.0 TECHNICAL CHARACTERISTICS
The PCA Directly Measures and Displays:
• Oxygen content in flue gas in the r ang e of 0. 1 to 20. 9 % O
• Flue gas temperature in the range of 0 to 2192 ºF (–18 to 1200 ºC)
• Primary-air / ambient temperature is in the range of 0 to 999 ºF
(–18 to 999 ºC)
2
Optional . . .
• Differential Pressure and Draft in the range of ±28" H2O (±70.0 mb)
• Carbon Monoxide* content in flue gas in the range of 0 to 4000 ppm
• Nitric Oxide* content in flue gas in the range of 0 to 1000 ppm
The PCA Computes and Displays:
When the measured oxygen level is not above 16.0%, and the Stack (Flue
Gas) temperature is not above 1832 °F (1000 ºC)
• Efficiency in the range of 0.1 to 99.9%
• Excess Air in the range of 1 to 250%
• Carbon Dioxide content in flue gas from 0.1 to a fuel dependent
maximum value in percent
• Carbon Monoxide* content referenced to a percentage of Oxygen in
the range of 0
• Nitrix Oxide* content referenced to a percenage of Oxygen in the
range of 0 to 9,999 ppm on analyzers equipped with a NX sensor.
Standard Fuels** Available for
Combustion Calculations:
• Natural Gas
• Oil #2
• Oil #4
• Oil #6
•
Kerosene
• Propane
• Coal
* For the PCA 30, 35, 60, & 65, the display can be set up to show
either measured values of Carbon Monoxide and Nitric Oxide (C O
& NX), or show the calculated values of these gases (CF & NF)
referenced to Oxyge n. In either case, all v alues are list ed on the
printout of analzyers equipped with a printer.
** Custom fuels available upon request. Contact factory for details.
Instruction 0024-9219
to 9,999 ppm on analyzers equipped with a CO sensor.
2-1
Technical Characteristics
Normal Operating Conditions:
Temperature:
Analyzer
Probe Tip
...................
..................
32 to 104 ºF (0 to 40 ºC)
1472 ºF (800 ºC) Max.
Humidity:
Analyzer
...................
15 to 90% Relative Humidity, Non-Condensing
Air Pressure:
Analyzer
Probe .........................
Performance:
Accuracy:
Oxygen*
Carbon Monoxide
Nitric Oxide
Flue Gas Temp.
Ambient Temp.
Pressure
...................
Atmospheric
10" H2O (25 mb) draft max at probe tip
.................... ±0.3% O
.....
±5% of reading or ±10 ppm, whichever is greater
between 0 – 2000 ppm, and ±10% of reading
between 2001 – 4000 ppm.
..............
...................
±5% of reading or ±5 ppm, whichever is greater
........
±4 ºF between 32 and 255 ºF
±6 ºF between 256 and 480 ºF
±8 ºF between 481 and 752 ºF
........
±2 ºF between 32 and 212 ºF
±2% of reading or ±0.02 inches of Water Column
(±0.05 mb), whichever is greater
2
(±2 ºC between 0 and 124 ºC)
(±3 ºC between 125 and 249 ºC)
(±4 °C between 250 and 400 °C)
(±1 °C between 0 and 100 °C)
System Flow Rate:
With
probe ................ 200
Front Panel Controls:
Seven embossed pushbutton switches with tactile feedback (refer to
Section 4.3)
Display:
20 character by 4 line alphanumeric LCD panel with a green backlight.
* Accuracy referenced in practical flue gas concentrations
(mixtures of O2, CO2 and N2)
2-2
cc/min minimum
Instruction 0024-9219
PCA
PCA
Technical Characteristics
Power Requirements:
Four AA alkaline batteries. Battery backup for the real-time clock, RAM,
and bias voltage for the Nitric Oxide sensor is provided by internal
batteries. Optional AC Power Supplies (110 VAC & 230
available.
lithium
VAC) are also
Operating Time:
A fresh set of batteries will provide at least 8 hours of continuous opera-
tion with the pump running and the backlight turned on.
Warm Up Time:
60 seconds.
Printer Interface:
Infrared Communications (refer to Section 4.24).
Materials:
• High impact ABS plastic case
• Polycarbonate window over the display
• Nickel plated, brass quick-connect hose fitting
• Stainless steel probe
Dimensions:
Height:
Width:
Depth:
.................. 8.5
...................
................... 2
in. (215 mm)
3.8 in. (96 mm) at display (3.0 in. [75 mm] at controls)
in. (50 mm)
Weight:
With Batteries:
Instruction 0024-9219
.....
Approximately 1.5 lbs (0.7 Kg)
2-3
Technical Characteristics
2-4
PCA
NOTES:
Instruction 0024-9219
PCA
3.0 SETTING UP THE PCA
3.1 Scope
Before using the PCA, y ou MUS T:
• Check the batteries or plug in an Optional Power Supply (Section 3.2)
• Connect the probe to the analyzer (Section
• Check the analyzer’s config uration ( Secti on 3.4)
3.2 PCA Power
3.2.1 Checking and Replacing the Batteries
A fresh set of batteries is supplied with the PCA. Install the batteries as
described below. If a LOW BATTERY
analyzer is turned on, replace the batteries.
1.
Remove the battery cover from the back of the PCA (Figure 3-1).
2.
Remove (and properly dispose of) any old batteries.
3.
Insert a fresh set of four AA alk aline b atter ies, mak ing su re to inst all
them per the “+” and “–” markings shown in the battery compartment.
4.
Replace the battery cover.
Figure 3-1. Battery Replacement
Instruction 0024-9219
3.3)
message is displayed when the
Setup
3-1
Setup
3.2.2 Using the Optional Power Supply
If an Optional Power Supply is to be used:
1.
Connect the output plug of the Optional Power Supply to the
analyzer’s power supply jack (Figure 3-2).
2.
Plug the Optional Power Supply into an appropriate AC wall outlet.
The analyzer will now operate and function normally.
3.3 Connecting the Probe
To attach the probe to the analyzer (Figure 3-2):
1.
Push the yellow-banded, quick-connect Flue Gas Hose (giving a slight
twist) onto the analyzer’s GAS sample-inlet fitting.
2.
Push the blue-banded, quick-connect Draft Hose (giving a slight twist)
onto the analyzer’s DRAFT sample-inlet fitting.
3.
Push the Flue Gas Thermocouple int o the T- ST AC K jack (c onnec tor
fits in only one way).
NOTE:
Perform Step 4 only if the Optional Room Air/Primary Air
Thermocouple is used.
The PCA has a built in room- air th ermo coup l e.
4.
Push the Optional Room Air/Primary Air Thermocouple into the
T-AIR jack (connector fits in only one way).
NOTE:
tion efficiency when the burner’s primary-air temperature is
not the same as room temperature, the primary-air tempera-
ture should be measured using the optional Primary Air
Thermocouple.
Inspect all the hoses for cracks. If any hose is defec tive, repl ace the en tire
probe assembly. Check that the water trap is empty, and the filter is not
dirty or saturated with water.
3-2
In order for the PCA to correctly calculate combus-
Instruction 0024-9219
PCA
PCA
Power Supply
110V/60Hz
230V/50Hz
(Optional)
Instruction 0024-9219
Flue Gas
Thermocouple
Water
Trap / Filter
Assembly
Figure 3-2. Connecting the Probe to the Analyzer
Flue Gas
Hose
Flue
Gas
Hose
Setup
Reset Button
Draft Hose
*
Present only on analyzers
equipped with a pressure
sensor.
Pressure Reference Port
(Used in the Measurement
of Differential Pressure)
*
Probe Tube
Room Air /
Primary Air
Thermocouple
(Optional)
*
Adjustable
Probe Stop
Probe
Handle
3-3
Setup
3.4 Configuring the PCA
The PCA is configured at the factory for the parameters shown below.
These parameters, however, can be changed by following the instructions
in their associated sections.
Function
Fuel
Temperature
Draft
Oxygen Reference
Language
Display
Time
Date
3-4
0
Mode
Parameters
Natural Gas
º
C
W
C
%
English
CO & NX
HR:MIN:SEC AM/PM
MM/DD/YY
To Change,
Refer to . . .
Section
Section 4.13
Section 4.14
Section
Section 4.16
Section
Section
Section 4.18
4.8
4.15
4.17
4.18
Instruction 0024-9219
PCA
PCA
4.0 OPERATION
4.1 Key Pad Functions
Operation
Descriptions of the key pad functions are given below. Note that most of
the front panel key pad buttons perform multiple functions as determined
by what screen is being displayed at the time.
Turns the analyzer ON and OFF. Note tha t ther e is a 5 second
OFF-delay that allows an operator to turn the instrument back
ON by pressing the
loss of test data if the analyzer is turned OFF by mistake.
Moves the cursor [z] in front of a menu item up through the
displayed items. This key also increases alphanumeric values in
screens requiring a value change.
Moves the cursor [z] in front of a menu item down through the
displayed items. This key also decreases alphanumeric values in
screens requiring a value change.
Chooses the highlighted item (the item with the cursor [z] in front
of it) in all menus and screens. This key als o causes th e cursor t o
enter the number field in the Password Screen, and causes the
cursor to advance to the next field position in screens requiring
multiple alphanumeric entries.
Starts and stops a combustion test when the Combustion Test
Screen is displayed. Pressing this key in any other screen almost
always returns the instrument to the Combustion Test Screen.
However, there are four situations where this key behaves as an
enter key: 1)
Screen, press the RUN key to display the first calibration screen.
2)
After entering an offset or span value in any of the Calibration
Edit Screens, press the
entering a time or date value in the Time/Date Setup Screen,
press the
the left side of the display. 4)
Setup or User Name Screens, press the
Advances the display to the nex t menu scr e en.
Turns the screen’s backlight ON and OFF.
Instruction 0024-9219
RUN key to store the new values and return the cursor to
RUN
key. This feature prevents the accidental
After entering a correct password in the Password
RUN key to store the new values. 3) After
After entering text in either the ID
RUN key to store the text.
4-1
Operation
4.2 Sampling Hole Location
The analyzer requires that a ½" diameter sampling hole be made in the
furnace stack to accommoda te t he p robe stop o n t he P robe a nd Hose
Assembly.
Locate the sampling hole downstream from the last heat exchanger,
and upstream from any source of dilution, such as a draft diverter
(Figure 4-1)
For residential and light-commercial combustion-equipment applications,
the following recommendations are applicable:
• Oil Gun Burners
stream from the furnace breaching, and at least 6 in. (15 cm) upstream
from the furnace side of the draft regulator.
• Gas Burners
at least 6 in. (15 cm) upstream from
the furnace side of the draft diverter
on gas-converted units. For gasdesigned equipment, the probe may
be inserted down into the flue
through the draft diverter or hood.
4-2
.
Important!
As the distance between the last heat exchanger
and sampling point increases, stack loss will falsely decrease
due to heat loss by convection from the flue or stack.
– Locate sampling hole at least 12 in. ( 30 cm) do wn-
– Locate sampling hole
FLUE GAS FLOW
(Downstream)
DRAFT
DIVERTER/
REGULATOR
SAMPLE
(Upstream)
FURNACE
BREECHING
Figure 4-1. Sampling Hole Location
POINT
Instruction 0024-9219
PCA
PCA
4.3 Performing a Combustion Test
Important!
analyzer can affect its accuracy. This is important to know if
the analyzer is stored in a cold place (such as an unheated
vehicle in the winter) and then taken into a warm furnace
area. For the most accurate test results, allow the analyzer to
warm up to room temperature before use (about 10 minutes).
4.3.1 Analyzer Turn On and Warm Up
Important!
performing the following steps.
1.
Make sure that the analyzer is properly set up per Section
2.
Place probe in an area of fresh, ambient air; then press the analyzer’s
ON/OFF
key.
3.
Wait for the analyzer to countdown through its 60 second warm-up
period; then perform one of the following:
•
If no errors were detected during warm-up,
Test Screen will be displayed. Skip Step 4, and go to Section
•
If an error was detected during warm-up,
4.
If one or more errors were detected by the analyzer’s microprocessor
during warm-up, these errors will be displayed at the bottom of the
Sensor Status Screen (Section 4.6). Address any problems now per
Section 7.2; then repeat this procedure starting with Step 1.
NOTE:
instrument can still perform any test not using the function
disabled by the error.
Instruction 0024-9219
Large rapid changes in the temp er atu re of t he
Be sure the probe is at room temperature before
3.0.
the Combustion
proceed with Step
If the error detected is not critical to your test, the
Operation
4.3.2.
4.
4-3
Operation
4.3.2 Installing Probe in the Stack
1.
After making a sampling hole in the stack (Section 4.2), and turning
on the analyzer (Section 4.3.1), screw the pro be stop supplie d with the
Probe and Hose Assembly into the sampling hole (Figure
2.
Insert the probe through the hole in the probe stop, then position the
probe tip inside the stack, near its center. Tighten the thumbscrew on
the probe stop to secure the probe.
4-2).
PROBE STOP
THUMBSCREW
Figure 4-2. Installing the Probe
4-4
Instruction 0024-9219
PCA
PCA
4.3.3 Starting a Combustion Test
Important!
the same as the room temperature, then be sure the Optional
Room Air / Primary Air Thermocouple is installed per
Section 3.3.
1.
With the Combustio n Test S creen (Se ction 4.7) displayed and the probe
installed in the stack, press the
2.
Once all sensor readings are displa yed: A) L oosen the thum bscre w on
the probe stop. B) Move the probe in and out of the stack until the
highest stack temperature (TS) reading is obtained. C) Tighten the
thumbscrew to prevent further movement of the probe.
Alternately, the highest stack temperature can be located by displaying the Draft Screen (Section 4.9) and adjusting the probe for the
highest HOT SPOT
Note that locating the highest stack temperature is very important for
accurate combustion calculations.
3.
You can now begin burner-service procedures. The readings on the
analyzer change quickly to show changes in burner performance.
If the burner’s primary-air temperature is not
RUN
key to start a combustion test.
reading.
CAUTION
With the Water Trap / Filter Assembly stood up on its Outlet
End, do not let water condensate build up beyond the tip of
the riser tube. The sensors could be damaged if water would
enter the analyzer. Drain the water condensate after every
combustion test (refer to Section 6.4).
4.
Pressing the
while a test is in progress. Mov ing th e curs or (z) in front of the print
(
P
) function using the
current test information to an optional printer.
ENTER key
will save
s
key, and then pressing
the Combustion Test Screen readings
ENTER
will print the
4.3.4 Ending a Combustion Test
1.
Press the
stop running.
RUN
key to end a combustion test. You should hear the p ump
Instruction 0024-9219
Burn hazard! Allow a hot probe to cool before handling.
WARNING!
Operation
4-5
Operation
CAUTION:
Do not place a hot probe inside the instrum en t’s ca rrying
case. Allow the probe to cool before storage.
2.
Loosen the thumbscrew on the probe stop; then remove the probe and
probe stop from the stack.
3.
If data was saved during the combustion test, you can turn off the
analyzer and review or print the stored data at a later time as described in Sections 4.10 and 4.23.
4.3.5 Turning Off the Analyzer and
Purging the CO Sensor
Turn off the analyzer by pressing the
If the
ON/OFF key is pressed while the CO reading is 100 ppm or higher, the
pump will automatically turn on (if not already running) to purge the
analyzer of CO.
Important!
during the purging process to allow fresh air to be drawn
through the analyzer.
The probe must be removed from the stack
ON/OFF
key.
The following message is displayed while the analyzer is being purged.
PURGING CO SENSOR
As soon as the CO level falls below 100 ppm, the pump t urns off and the
analyzer starts its normal 5 second turn-off sequence.
To abort the purging process and immediately start the analyzer’s turn-off
sequence, press the
ON/OFF key again.
NOTE:
during which time the unit can be turned on again without
any warm-up time. Press the
back on during this 5-second delay.
4-6
Turning the analyzer off initiates a 5-second delay,
RUN
key
to turn the analyzer
Instruction 0024-9219
PCA
PCA
4.4 Differential Pressure Measurement
Operation
The difference in pressure (P) between two areas can be measured by
using the PCA’s two pressure ports and DRAFT Screen. By using Pressure
Port
2 (–)
as the reference, the pressure applie d to Port 1 (+)
displayed on the DRAFT Screen as the differential pressure b etween the
two ports.
1.
Turn on the analyzer by pressing the
cycle to complete; then press the
ON/OFF ke
MENU
key until the first DRAFT
y; wait for the warm-up
Screen is displayed (refer to Section 4.9). If a TA-SENSOR ERROR is
displayed, as the result of the probe’s thermocouple not being plugged
into the analyzer, press the
pressing the
MENU
key
RUN
key
to acknowledge the error before
.
2.
While the first DRAFT Screen is displayed, remove any hoses connected to Pressure Ports 1 and 2; then press the
these ports to atmospheric pressure.
ENTER
key to zero
3.
Connect two sampling hoses to Pressure Ports 1 and 2 (Figure 4-3).
Then place the open end of ea ch h ose in to the a reas b ein g mea sure d.
4.
The differential pressure between
the two areas is now displayed on
the third DRAFT Screen. If the
pressure at Port 1 is higher than
Port 2, then the pressure difference will be positive
. But if the
DRAFT
DRAFT
–
0.95 WC
HOT SPOT ---- °C P
«
pressure at Port #1 is lower, then the pressure difference will be
negative
pressure at Port
. The reading shown in this example indicates that the
1 is 0.95" H2O
lower than the pressure at Port
Sampling Hoses with quickconnect fittings are available
as an optional accessory.
Refer to Section 8.2 .
Pressure Port 1(+)
Pressure Port 2(–)
Reference
Figure 4-3. Differential Pressure Hose Connections
Instruction 0024-9219
will be
2.
S
4-7
Operation
4.5 Warm-up Screen
BACHARACH, INC.
PCA xx
WARMUP yy
Where: xx = Instrument Model Number
yy = Counts down from 60 seconds
As soon as the ON/OFF
software version number are dis play ed f or ap proxi mat ely 3 s ec onds . To
continuously display these items, hold down the
The warmup cycle continues after the
The Warmup Screen is displayed during the an alyzer’s 60 second warm up
cycle, during which time the “Warmup” value (yy) counts down to zero.
After the warmup cycle is complete, (and if the unit is working correctly)
the instrument will flash NO ERRORS DETECTED
the Combustion Test Screen (Section 4.7). If there is a problem, however,
with one or more of the sensors, the Sensor Status Screen (Sect ion 4.6) is
displayed.
key is
pressed, the instrument’s serial number and
ON/OFF
ON/OFF
key is released.
key at
and go directly to
start-up.
Front Panel Key Functions:
–
No Action
–
No Action
–
No Action
–
No Action
–
No Action
Toggle Backlight ON/OFF*
–
–
Turn analyzer OFF*
* The
LIGHT
button will always turn the backlight on and off, while the
key
will always turn the analyzer on and off. These two keys will not be
mentioned in the remainder of this section.
4-8
ON/
OFF
Instruction 0024-9219
PCA
PCA
4.6 Sensor Status Screen
BACHARACH, INC.
PCA xx
WARMUP 0
z
Where: xx = Instrument Model Number
z = Sensor(s) in error
Operation
If a problem with one or more of the sensors was detected during
warmup, the Sensor Status Screen will display an error code for those
sensors at the bottom of the screen and wait for operator intervention.
Refer to Section 7.2 for a listing and explaination of the error codes.
Note that the analyzer will not
Test Screen if a sensor error was detected. The analyzer, however, can
still be used to perform any test that does not depend on the sensor that
is in error. Press the
screen to continue using the analyzer.
RUN
Front Panel Key Functions:
automatically switch to the Combustion
key to manually enter the Combustion Test
–
No Action
–
No Action
–
No Action
–
Go to Combustion Test Screen
–
No Action
Instruction 0024-9219
4-9
Operation
4.7 Combustion Test Screen
PCA models 10 thru 25, 40 thru 55 PCA models 30, 35, 60, & 65
O2 4.0 CO 12
C2 9.5 CF 15 NG
TA 68.0 TS 374
EF 82.6 EA 21 «S
This screen shows:
O2 ...............
C2 ...............
TA
...............
...............
EF
CO*
.............
CF*
.............
TS ...............
EA
............... Exces s a i r (%)
NX*
.............
NF*
.............
HLD/RUN
N
G ..............
P ..................
S
.................. Save
Oxygen content in flue gas (%)
Carbon Dioxide content
present in flue gas (%)
Primary/Ambient air temp. (°F)
Combustion efficiency (%)
Carbon Monoxide content in flue gas (pp m)
Carbon Monoxide content referenced to a percentage of O2 (ppm)
Stack (Flue gas) temperature (°F)
Nitric Oxide content in flue gas (ppm)
Nitric Oxide content referenced to a percentag e of O2 (ppm)
..
PCA on hold / PCA running test
Fuel code for natural gas (see Section 4.8 for other codes)
Print Data
* For PCA models 30, 35, 60 and 65, you have the option of displaying either
CO & NX, or CF & NF. Refer to Section 4.17 for setup instructions.
NOTE: Refer to Section 7.3 if stars (****) , dashes (– – –
or Xs (
Front Panel Key Functions:
Data
XXXX
) appear in the display.
–
4-10
Move cursor (z
–
Move cursor (z
Save or print screen data
–
Run test / hold test
–
–
Go to Fuel Selection Screen
HLD
P
) up
) down
O2 4.0 CO 12
C2 9.5 NX 10
TA 68.0 TS 374
EF 82.6 EA 21
- OR -
O2 4.0 CF 15 HLD
C2 9.5 NF 12 NG
TA 68.0 TS 374
EF 82.6 EA 21 «S
HL
N
«S
–) ,
Instruction 0024-9219
PCA
D
G
P
P
PCA
4.8 Fuel Selection Screen
«NATGAS FUEL
OIL #2 KEROSENE
OIL #4 PROPANE
OIL #6 COAL
This screen is displayed by pressi ng th e
Test Screen, and is used to select the fuel being burned.
To select a fuel, first use the
desired fuel, and then press the
st
keys
ENTER
NOTE:
mains in memory after the PCA is turned off.
The fuel selected is saved as the default, and re-
MENU
key from the Combustion
to move the cursor (z) in front of the
key.
The fuel codes as displayed in the Combustion Test Screen:
NG = Natural Gas
O#2= Oil #2
O#4= Oil #4
O#6= Oil #6
Front Panel Key Functions:
KER =
Kerosene
LPG = Propane
COL = Coal
–
Move cursor
(z) up
–
Move cursor
(z) down
–
Select Fuel
–
Go to Combustion Test Screen
– Go to
Instruction 0024-9219
Draft Screen for PCAs with a pressure sensor, or the
Memory Directory Screen for PCAs without a pressure
sensor
Operation
4-11
Operation
4.9 Draft Screens
(For PCA Models 15, 25, 35, 45, 55 & 65)
The first Draft Screen is displayed by
repeatedly pressing the
the Combustion Test Screen.
To measure draft, first zero the
analyzer’s pressure sensor to atmospheric pressure by disconnec ting th e
draft hose from the bottom of the
instrument, and then pressing the
ENTER
key. Reconnect the draft hose
after the second Draft Screen appears
(shown for 3 seconds). The third
screen shows the current values of
draft and stack temperature as
measured by the analyzer.
When using the analyzer to make a
differential pressure measurement
(Section 4.4), the differential pressure
value will appear on the third Draft
Screen.
To save (S) or print (P) the screen
data, first use the
the cursor (z) in front of the desired
function, and then press the
key.
Front Panel Key Functions:
–
4-12
Move cursor
–
Move cursor
Save or Print screen dat a
–
Go to Combustion Test Screen
–
–
Go to Memory Directory Screen
MENU
st
keys to move
(z) up
(z) down
key from
ENTER
PCA
DRAFT
DISCONNECT DRAFT
HOSE
PRESS ENTER
DRAFT
RECONNECT DRAFT
HOSE
DRAFT
DRAFT
HOT SPOT
–
0.25 XX
190 °C
Where: xx = Unit of measure.
Default is inches of water
column (WC). See Optional
Draft SETUP Screen (Section
4.14) for other choices.
Instruction 0024-9219
P
«
S
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